11 65 020 Removing and installing/replacing exhaust turbocharger (N55) all-wheel drive vehicle

WARNING: The module consists of exhaust turbo charger and exhaust manifold.
The weight of the turbocharger is approx. 15 kg.

Necessary preliminary work:

Drain COOLANT .
Remove COOLANT THERMOSTAT .
Remove COOLANT PUMP .
Remove CHARGE AIR COOLER .
Remove CATALYTIC CONVERTERS

Release screws (1).

Tightening torque 11 53 4AZ .

Fig 1: Identifying Screws

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Release screw (1).

Tightening torque 11 53 10AZ .

If necessary, use appropriate tool to loosen coolant return line (3) and coolant flow line (2) at connection point.

Installation note:

Replace sealing rings.

Fig 2: Identifying Coolant Return Line

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Release screw (1).

Loosen screws (3) but do not remove.

Fig 3: Identifying Screws

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Release screw (1).

Tightening torque 11 42 6AZ .

If necessary, use appropriate tool to loosen connection of oil return lines (2).

Installation note:

Replace sealing ring.

Fig 4: Identifying Oil Return Line And Screw

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Release screw (1).

Tightening torque 11 42 7AZ .

If necessary, use appropriate tool to loosen connection of oil return lines (2).

Possibility of oil escaping when oil return line is disconnected.

Installation note:

Replace sealing ring.

Fig 5: Identifying Oil Return Line And Screw

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Release screw (1).

Tightening torque: 11 42 4AZ .

If necessary, use appropriate tool to loosen coolant return lines (2) at connection point.

Installation note:

Replace sealing ring.

Fig 6: Identifying Coolant Return Line And Screw

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Loosen plug connection (1) at blow-off valve.

Release screw (2).

Tightening torque 11 65 4AZ .

If necessary, use appropriate tool to loosen oil feeder lines at point of connection (3).

Fig 7: Identifying Oil Return Line And Screw

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Possibility of oil escaping when oil return line is disconnected.

Installation note:

Replace sealing ring.

Disconnect vacuum line (1) from vacuum unit.

Fig 8: Identifying Vacuum Line

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Disconnect vacuum line (1) from cylinder head cover.

Fig 9: Identifying Vacuum Line And Cylinder Head Cover

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Remove heat shield (1).

Tightening torque: 11 65 2AZ

Loosen all flange nuts (2) along the line.

Remove module by maneuvering downwards on gearbox side.

NOTE: Total weight of module is approximately 15 kg .

Fig 10: Locating Flange Nuts

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NOTE: Oil supply line (2) can only be replaced after removal of the turbocharger.

Release screw (1).

If necessary, use appropriate tool to loosen oil feeder lines at point of connection (2).

Fig 11: Identifying Oil Supply Line And Screws

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Installation note:

Replace all sealing rings (1).

Fig 12: Identifying Sealing Rings

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Installation note:

Replace all graphite seals (1).

Fig 13: Identifying Graphite Seals

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Position turbocharger on cylinder head and hold in place with two bolts.

Insert bolt (1) but do not tighten at this point.

Fig 14: Identifying Screws

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IMPORTANT: The module consists of exhaust turbocharger and exhaust manifold and must be installed stress-free.
Torque and tightening sequence must be observed without fail.
Tightening torque: 11 65 1AZ .

Join all flange nuts in sequence 1 to 15 to 8 Nm .
Tighten all flange nuts to a torque of 13 Nm in sequence (1 to 15).

Fig 15: Exhaust Manifold Flange Nuts Tightening/Loosening Sequence

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Installation note:
Flange nuts 1 to 5 are accessible from above.
Flange nuts 6 to 15 are accessible from below.

Secure screws (3).

Tightening torque: 11 65 9AZ .

Tighten bolt (1).

Tightening torque 11 65 8AZ .

Fig 16: Identifying Screws

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Assemble engine.

Observe BMW Diagnosis System instruction.

Carry out BMW leakage test for intake system.